Aluminum alloy article having low texture and methods of making the same

ABSTRACT

Provided herein are aluminum alloys having a uniform surface recrystallization texture. The uniform surface recrystallization texture can be provided by methods described herein. Also provided herein are methods to produce aluminum alloys having a uniform surface recrystallization texture, which may include homogenizing and hot rolling an aluminum cast product to a final gauge at a temperature greater than or about a recrystallization temperature.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. ProvisionalApplication No. 62/515,714, filed on Jun. 6, 2017, which is herebyincorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to metallurgy generally and morespecifically to metal manufacturing. In certain aspects, the disclosureprovides rolled aluminum alloy articles having a rolled surface havinglow texture (e.g., recrystallization texture). In certain aspects, thedisclosure also provides methods of making such articles. In certainother aspects, the disclosure provides various end uses of sucharticles, such as in automotive, transportation, electronics, andindustrial applications.

BACKGROUND

Aluminum alloy articles are desirable for use in a number of differentapplications, such as those where strength and durability are especiallydesirable. For example, aluminum alloys are commonly used for automotivestructural applications in place of steel. Because aluminum alloys aregenerally about 2.8 times less dense than steel, the use of suchmaterials reduces the weight of the vehicle and allows for substantialimprovements in its fuel economy. Even so, the use of currentlyavailable aluminum alloys in automotive and other applications posescertain challenges.

One such challenge relates to the emergence of recrystallization textureduring the processing (e.g., rolling) of the aluminum alloy article,which leads to a high degree of anisotropy on the surface of thearticle. Thus, aluminum alloy rolled articles (e.g., aluminum alloyplates, aluminum alloy shates, and aluminum alloy sheets) can havesignificant amounts of recrystallization texture that develops duringthe course of processing.

SUMMARY

Texturing of aluminum alloy rolled articles can modify the mechanical,strength, and forming properties. Thus, it may be desirable to providean aluminum alloy rolled article having a surface that is nearlyisotropic and thus, possessing nearly uniform surface properties. Thepresent disclosure provides aluminum articles with surfaces, or portionsthereof, that are substantially free of recrystallization texture, aswell as methods for making and using such articles.

The term embodiment and like terms are intended to refer broadly to allof the subject matter of this disclosure and the claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of theclaims below. Embodiments of the present disclosure covered herein aredefined by the claims below, not this summary. This summary is ahigh-level overview of various aspects of the disclosure and introducessome of the concepts that are further described in the DetailedDescription section below. This summary is not intended to identify keyor essential features of the claimed subject matter, nor is it intendedto be used in isolation to determine the scope of the claimed subjectmatter. The subject matter should be understood by reference toappropriate portions of the entire specification of this disclosure, anyor all drawings and each claim.

Embodiments of the present disclosure include an aluminum alloy rolledarticle comprising a rolled surface, such as a rolled surface thatcomprises a first surface portion that is substantially free ofrecrystallization texture. In some non-limiting examples, the firstsurface portion can have an isotropic texture, such as an isotropictexture that comprises a plurality of texture components. As examples,different texture components may comprise less than or about 1 volumepercent (vol. %) of the first surface portion. In some aspects, theplurality of texture components comprise surface texture componentsselected from the group consisting of a cube component, a gosscomponent, a brass component, an S component, and a copper component.For example, in one embodiment, an aluminum alloy rolled articlecomprises a rolled surface with at least a portion that is free orsubstantially free of recrystallization texture and includes less thanor about 1 volume percent (i.e., between 0 and 1 volume percent) of acube texture component, a goss texture component, a brass texturecomponent, an S texture component, and a copper texture component.

Surfaces having significant amounts of cube or other texture components,in embodiments, may correspond to surfaces that do not have an isotropictexture. Stated another way, surfaces including significant amounts ofcube or other texture components may exhibit Langford coefficients(R-value) that are lower in a direction diagonal from a longitudinaldirection (rolling direction) of the surface than those along thelongitudinal direction or along a transverse direction (perpendicular tothe rolling direction). By generating an aluminum alloy rolled articlewith low amounts of surface texture or with randomized surfacetexturing, the articles can exhibit isotropic properties in which theLangford coefficients do not significantly vary as a function of anglefrom the longitudinal direction.

The first surface portion optionally has one or more surface textureratios between 0.80 and 1.25. In embodiments, a surface texture ratiocorresponds to a relationship between volume percentages of a firstsurface texture and a second surface texture. In some non-limitingexamples, the first surface portion has a cube component to brasscomponent ratio of from 0.80 to 1.25, a cube component to goss componentratio of from 0.80 to 1.25, a cube component to S component ratio offrom 0.80 to 1.25, a cube component to copper component ratio of from0.80 to 1.25, a goss component to brass component ratio of from 0.80 to1.25, a goss component to S component ratio of from 0.80 to 1.25, a gosscomponent to copper component ratio of from 0.80 to 1.25, a brasscomponent to S component ratio of from 0.80 to 1.25, a brass componentto copper component ratio of from 0.80 to 1.25, an S component to coppercomponent ratio of from 0.80 to 1.25, a cube component to goss componentto brass component ratio of from 0.80 to 1.25, a cube component to gosscomponent to S component ratio of from 0.80 to 1.25, a cube component togoss component to copper component ratio of from 0.80 to 1.25, a gosscomponent to brass component to S component ratio of from 0.80 to 1.25,a goss component to brass component to copper component ratio of from0.80 to 1.25, a brass component to S component to copper component ratioof from 0.80 to 1.25, a cube component to goss component to brasscomponent to S component ratio of from 0.80 to 1.25, a cube component togoss component to brass component to copper component ratio of from 0.80to 1.25, a goss component to brass component to S component to coppercomponent ratio of from 0.80 to 1.25, or a cube component to gosscomponent to brass component to S component to copper component ratio offrom 0.80 to 1.25. By controlling the amounts and ratios of differenttexture components, the aluminum rolled article may exhibit moreisotropic properties.

In some non-limiting examples, the aluminum alloy rolled article canhave any suitable width or length. Optionally, the alloy of the aluminumalloy rolled article is a 5xxx aluminum alloy or a 6xxx aluminum alloy.In some further examples, the aluminum alloy rolled article can beproduced without cold rolling (i.e., hot rolled to a final gauge).Stated another way, the aluminum alloy rolled article may optionally beformed by a process that does not use cold rolling of the article to afinal gauge or thickness. In some non-limiting examples, the aluminumalloy rolled article described herein can be formed by a process thatcomprises providing a molten aluminum alloy composition, continuouslycasting the molten aluminum alloy composition to form an aluminum alloycast product, homogenizing the aluminum alloy cast product to form ahomogenized aluminum alloy cast product, and rolling the homogenizedaluminum alloy cast product to form the aluminum alloy rolled articlehaving a thickness of no more than 7 mm, such as between 0.01 mm and 7mm, between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mmand 4 mm, between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm.Advantageously, the rolling may be carried out at a temperature of noless than 300° C., such as between 300° C. and 550° C. Rolling atelevated temperatures may be useful, in embodiments, for preventing orreducing recrystallization and associated texturing of the aluminumalloy rolled article.

In some non-limiting examples, a method for making an aluminum alloyrolled article comprises providing a molten aluminum alloy composition,continuously casting the molten aluminum alloy composition to form analuminum alloy cast product, homogenizing the aluminum alloy castproduct to form a homogenized aluminum alloy cast product, and rollingthe homogenized aluminum alloy cast product to form an aluminum alloyrolled article having a thickness of no more than 7 mm, such as between0.01 mm and 7 mm, between 0.01 mm and 6 mm, between 0.01 mm and 5 mm,between 0.01 mm and 4 mm, between 0.01 mm and 3 mm, or between 0.01 mmand 2 mm, wherein the rolling is carried out at a temperature of no lessthan 300° C., such as between 300° C. and 550° C. Following the rolling,the rolled aluminum alloy rolled article can optionally be subjected toquenching. In some examples, direct chill casting is not utilized. Insome examples, the aluminum alloy rolled article is rolled to a finalthickness during the rolling and a subsequent cold rolling process isnot used to achieve the final thickness of the aluminum alloy rolledarticle.

Optionally, homogenizing the aluminum alloy cast product includescontrolling a homogenization temperature of the aluminum alloy castproduct, such as after exiting from a continuous caster. Optionally, thehomogenization temperature is between 400° C. and 600° C., between 450°C. and 600° C., between 400° C. and 500° C., or between 500° C. and 600°C. In some examples, the aluminum alloy cast product is not cooled tobelow 400° C. before the homogenizing (i.e., between the casting and thehomogenizing). In other examples, however, the aluminum alloy castproduct may be cooled to below 400° C. before the homogenizing (i.e.,between the casting and the homogenizing).

Optionally, rolling the homogenized aluminum alloy cast product includescontrolling a rolling temperature during rolling. For example, astarting temperature of the rolling is optionally between 400° C. and550° C. Optionally, an exit or finishing temperature of the rolling isbetween 300° C. and 500° C. In some examples, rolling the homogenizedaluminum alloy cast product includes maintaining the temperature at orabove a recrystallization temperature of the homogenized aluminum alloy.

In some non-limiting examples, provided herein is an aluminum alloyrolled article, which is formed by a process comprising providing amolten aluminum alloy composition, continuously casting the moltenaluminum alloy composition to form an aluminum alloy cast product,homogenizing the aluminum alloy cast product to form a homogenizedaluminum alloy cast product, and rolling the homogenized aluminum alloycast product to form the aluminum alloy rolled article having athickness of no more than 7 mm, such as between 0.01 mm and 7 mm,between 0.01 mm and 6 mm, between 0.01 mm and 5 mm, between 0.01 mm and4 mm, between 0.01 mm and 3 mm, or between 0.01 mm and 2 mm, with therolling carried out at a temperature of no less than 300° C., such asbetween 300° C. and 550° C. In some non-limiting examples, the processdoes not comprise direct chill casting. In some further non-limitingexamples, the continuously casting comprises using or use of twin-beltcontinuous casting. In some further non-limiting examples, the processdoes not comprise cold rolling.

In some aspects, the aluminum alloy rolled article comprises a firstsurface portion, such as a first surface portion that is substantiallyfree of recrystallization texture. Optionally, the first surface portionhas an isotropic texture, such as an isotropic texture that comprises aplurality of texture components. For example, each texture component ofthe plurality of texture components may optionally comprise less than 1volume percent of the first surface portion. In some examples, thealuminum alloy rolled article may have an angularly uniform (isotropic)Langford coefficient (R-value), such as an R-value that does not varyappreciably (e.g., less than 10%, less than 5%, or less than 1%) alongan angle relative to the rolling direction. For example, R-values for anangularly uniform rolled aluminum article may advantageously varybetween 0% and 10% (e.g., 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or10%) at directions parallel to the rolling direction (longitudinal),perpendicular to the rolling direction (transverse), and at directionsbetween longitudinal and transverse directions (diagonal).

In some non-limiting examples, provided herein is an aluminum alloyarticle of manufacture. The aluminum alloy article of manufacture can bean automotive body part (e.g., a structural part or an outer panel). Thealuminum alloy article of manufacture can be an electronics devicehousing, an aerospace body part, a transportation body part, or acontainer part (e.g., a storage tank or an aluminum can). Aluminum alloyarticles of manufacture may optionally be formed from an aluminum alloyrolled article having a surface free or substantially free ofrecrystallization texture, such as by a technique involving subjectingan aluminum alloy rolled article having a surface free or substantiallyfree of recrystallization texture to a stamping, drawing, or otherforming process.

BRIEF DESCRIPTION OF THE DRAWINGS

The specification makes reference to the following appended figures, inwhich use of like reference numerals in different figures is intended toillustrate like or analogous components.

FIG. 1 provides a schematic overview of a method of and system formaking an aluminum alloy rolled article according to certain aspects ofthe present disclosure.

FIG. 2 is a graph comparing cube texture component to brass texturecomponent of aluminum alloys produced according to certain aspects ofthe present disclosure.

FIG. 3 is a graph for AA6451 alloys comparing cube texture component,goss texture component, brass texture component, S texture component andcopper texture component of aluminum alloys produced according tocertain aspects of the present disclosure.

FIG. 4 is a graph for AA6111 alloys comparing cube texture component,goss texture component, brass texture component, S texture component andcopper texture component of aluminum alloys produced according tocertain aspects of the present disclosure.

FIG. 5 is a graph for AA5754 alloys comparing cube texture component,goss texture component, brass texture component, S texture component andcopper texture component of aluminum alloys produced according tocertain aspects of the present disclosure.

DETAILED DESCRIPTION

Certain aspects and features of the present disclosure relate toaluminum alloy articles having isotropic surface textures. Aluminumalloy articles having isotropic surface textures can further haveisotropic mechanical properties, providing highly formable aluminumalloy articles. Further aspects and features of the present disclosurerelate to methods to produce aluminum alloy articles having isotropicsurface textures. Still further aspects and features of the presentdisclosure include aluminum alloy rolled articles having isotropicsurface textures.

Definitions and Descriptions

The terms “invention,” “the invention,” “this invention” and “thepresent invention” used herein are intended to refer broadly to all ofthe subject matter of this patent application and the claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of thepatent claims below.

In this description, reference is made to alloys identified by aluminumindustry designations, such as “series” or “6xxx.” For an understandingof the number designation system most commonly used in naming andidentifying aluminum and its alloys, see “International AlloyDesignations and Chemical Composition Limits for Wrought Aluminum andWrought Aluminum Alloys” or “Registration Record of Aluminum AssociationAlloy Designations and Chemical Compositions Limits for Aluminum Alloysin the Form of Castings and Ingot,” both published by The AluminumAssociation.

Aluminum alloys may described in terms of their elemental composition inweight percentage (wt. %) based on the total weight of the alloy. Incertain examples of each alloy, the remainder is aluminum, with amaximum wt. % of 0.15% for the sum of the impurities.

All ranges disclosed herein are to be understood to encompass any andall subranges subsumed therein. For example, a stated range of “1 to 10”should be considered to include any and all subranges between (andinclusive of) the minimum value of 1 and the maximum value of 10; thatis, all subranges beginning with a minimum value of 1 or more, e.g. 1 to6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.

As used herein, the meaning of “a,” “an,” or “the” includes singular andplural references unless the context clearly dictates otherwise.

As used herein, a plate generally has a thickness greater than about 15mm. For example, a plate may refer to an aluminum or aluminum alloyproduct or article having a thickness of greater than or about 15 mm,greater than or about 20 mm, greater than or about 25 mm, greater thanor about 30 mm, greater than or about 35 mm, greater than or about 40mm, greater than or about 45 mm, greater than or about 50 mm, or greaterthan or about 100 mm.

As used herein, a shate (also referred to as a sheet plate) generallyhas a thickness of from about 4 mm to about 15 mm. For example, a shatemay have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm,about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13mm, about 14 mm, or about 15 mm.

As used herein, a sheet generally refers to an aluminum (or aluminumalloy) cast product or article having a thickness of less than about 4mm. For example, a sheet may have a thickness of less than about 4 mm,less than about 3 mm, less than about 2 mm, less than about 1 mm, lessthan about 0.5 mm, less than about 0.3 mm (e.g., about 0.2 mm), orbetween 0.2 mm and 4 mm.

Reference may be is made in this application to alloy temper orcondition. For an understanding of the alloy temper descriptions mostcommonly used, see “American National Standards (ANSI) H35 on Alloy andTemper Designation Systems.” An F condition or temper refers to analuminum alloy as fabricated. An Hxx condition or temper, also referredto herein as an H temper, refers to a non-heat treatable aluminum alloyafter cold rolling with or without thermal treatment (e.g., annealing).Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9tempers. A T1 condition or temper refers to an aluminum alloy cooledfrom hot working and naturally aged (e.g., at room temperature). A T2condition or temper refers to an aluminum alloy cooled from hot working,cold worked and naturally aged. A T3 condition or temper refers to analuminum alloy solution heat treated, cold worked, and naturally aged. AT4 condition or temper refers to an aluminum alloy solution heat treatedand naturally aged. A T5 condition or temper refers to an aluminum alloycooled from hot working and artificially aged (at elevatedtemperatures). A T6 condition or temper refers to an aluminum alloysolution heat treated and artificially aged. A T7 condition or temperrefers to an aluminum alloy solution heat treated and artificiallyoveraged. A T8x condition or temper refers to an aluminum alloy solutionheat treated, cold worked, and artificially aged. A T9 condition ortemper refers to an aluminum alloy solution heat treated, artificiallyaged, and cold worked. A W condition or temper refers to an aluminumalloy after solution heat treatment.

As used herein, the term “substantially free of surface texture” refersto a characteristic of all or a portion of a surface of a prepared metalplate, shate, or sheet wherein no one of a cube texture component, agoss texture component, a brass texture component, an S texturecomponent, or a copper texture component is a predominant texturecomponent found within the portion of the surface of the prepared metalplate, shate or sheet. For example, a surface substantially free ofsurface texture may have low volume or areal percentages of a cubetexture component, a goss texture component, a brass texture component,an S texture component, and a copper texture component, such as lessthan or about 1 volume percent or less than or about 1 areal percent.

As used herein, the term “uniform thinning” refers to a rollingdeformation wherein a thickness of a prepared metal plate, shate, orsheet is decreased during rolling such that the thickness of a firstportion of the prepared metal plate, shate, or sheet remains within ±2%of a thickness of any other portion of the prepared metal plate, shate,or sheet. In some cases, uniform thinning may refer to a uniformity ofthe reduction of a thickness of a prepared metal plate, shate, or sheetupon being subjected to a tensile stress along a different directions(e.g., a longitudinal direction (rolling direction), a transversedirection (perpendicular to the rolling direction), or a diagonaldirection (direction between the transverse and longitudinaldirections). Optionally, a material that undergoes uniform thinning mayhave a Langford coefficient (R-value) that does not substantially varyas a function of angle (i.e., angle from the rolling direction).

As used herein, terms such as “cast product,” “cast metal product,”“cast aluminum product,” “cast aluminum alloy product,” “aluminum alloycast product,” and the like are interchangeable and may refer to aproduct produced by direct chill casting (including direct chillco-casting), semi-continuous casting, continuous casting (including, forexample, by use of a twin belt caster, a twin roll caster, a blockcaster, or any other continuous caster), electromagnetic casting, hottop casting, or any other casting method.

Aluminum Alloy Rolled Articles Aluminum Alloy Rolled Article Surface

In some non-limiting examples, an aluminum alloy rolled article having arolled surface can have at least a first surface portion that has lowvolume fractions of a cube texture component, a goss texture component,a brass texture component, an S texture component, and a copper texturecomponent, such as volume fractions that are between 0% and 1%, or thatis substantially free of recrystallization texture. In the context ofthe present disclosure, a surface portion that is substantially free ofrecrystallization texture refers to a surface portion that is uniformacross an area defined as the surface portion, wherein no onerecrystallization texture component is dominant. In some non-limitingexamples, a surface portion that has low volume fractions of a cubetexture component, a goss texture component, a brass texture component,an S texture component, and a copper texture component, such as volumefractions that are between 0% and 1%, or that is substantially free ofrecrystallization texture may refer to a surface portion in whichrecrystallization textures that exhibit angularly dependent Langfordcoefficients are present only in minor amounts such that the overallLangford coefficient of the surface portion is isotropic (i.e., notsubstantially angularly dependent or substantially angularly uniform).In some non-limiting examples, a surface portion can have an isotropictexture, wherein the isotropic texture comprises a plurality of texturecomponents, wherein each texture component comprises less than 1 volumepercent (vol. %) of the surface portion. In some aspects, the pluralityof texture components comprise surface texture components selected fromthe group consisting of a cube component, a goss component, a brasscomponent, an S component, and a copper component.

In some cases, the aluminum alloy rolled article described herein canhave an isotropic surface texture described as a ratio between eachtexture component. In some non-limiting examples, a surface portion canhave a ratio of the cube component to the brass component (and likewise,a ratio of the brass component to the cube component) of from 0.80 to1.25. For example, the surface portion can have a ratio of the cubecomponent to the brass component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85,0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97,0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09,1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21,1.22, 1.23, 1.24, or 1.25. In some examples, the ratio of the cubecomponent to the brass component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the goss component (and likewise, a ratio of thegoss component to the cube component) of from 0.80 to 1.25. For example,the surface portion can have a ratio of the cube component to the gosscomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the cube component to the gosscomponent can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the S component (and likewise, a ratio of the Scomponent to the cube component) of from 0.80 to 1.25. For example, thesurface portion can have a ratio of the cube component to the Scomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the cube component to the Scomponent can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the copper component (and likewise, a ratio of thecopper component to the cube component) of from 0.80 to 1.25. Forexample, the surface portion can have a ratio of the cube component tothe copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87,0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99,1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11,1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23,1.24, or 1.25. In some examples, the ratio of the cube component to thecopper component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe goss component to the brass component of from 0.80 to 1.25. Forexample, the surface portion can have a ratio of the goss component tothe brass component (and likewise, a ratio of the brass component to thegoss component) of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88,0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00,1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12,1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24,or 1.25. In some examples, the ratio of the goss component to the brasscomponent can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe goss component to the S component (and likewise, a ratio of the Scomponent to the goss component) of from 0.80 to 1.25. For example, thesurface portion can have a ratio of the goss component to the Scomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the goss component to the Scomponent can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe goss component to the copper component (and likewise, a ratio of thecopper component to the goss component) of from 0.80 to 1.25. Forexample, the surface portion can have a ratio of the goss component tothe copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87,0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99,1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11,1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23,1.24, or 1.25. In some examples, the ratio of the goss component to thecopper component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe brass component to the S component (and likewise, a ratio of the Scomponent to the brass component) of from 0.80 to 1.25. For example, thesurface portion can have a ratio of the brass component to the Scomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the brass component to the Scomponent can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe brass component to the copper component (and likewise, a ratio ofthe copper component to the brass component) of from 0.80 to 1.25. Forexample, the surface portion can have a ratio of the brass component tothe copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87,0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99,1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11,1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23,1.24, or 1.25. In some examples, the ratio of the brass component to thecopper component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe S component to the copper component (and likewise, a ratio of thecopper component to the S component) of from 0.80 to 1.25. For example,the surface portion can have a ratio of the S component to the coppercomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the S component to the coppercomponent can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the goss component to the brass component (or anysuitable ratio including the cube component, the goss component, and thebrass component) of from 0.80 to 1.25. For example, the surface portioncan have a ratio of the cube component to the goss component to thebrass component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88,0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00,1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12,1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24,or 1.25. In some examples, the ratio of the cube component to the gosscomponent to the brass component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the goss component to the S component (or anysuitable ratio including the cube component, the goss component, and theS component) of from 0.80 to 1.25. For example, the surface portion canhave a ratio of the cube component to the goss component to the Scomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the cube component to the gosscomponent to the S component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the goss component to the copper component (or anysuitable ratio including the cube component, the goss component, and thecopper component) of from 0.80 to 1.25. For example, the surface portioncan have a ratio of the cube component to the goss component to thecopper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87,0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99,1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11,1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23,1.24, or 1.25. In some examples, the ratio of the cube component to thegoss component to the copper component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe goss component to the brass component to the S component (or anysuitable ratio including the goss component, the brass component, andthe S component) of from 0.80 to 1.25. For example, the surface portioncan have a ratio of the goss component to the brass component to the Scomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the goss component to the brasscomponent to the S component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe goss component to the brass component to the copper component (orany suitable ratio including the goss component, the brass component,and the copper component) of from 0.80 to 1.25. For example, the surfaceportion can have a ratio of the goss component to the brass component tothe copper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87,0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99,1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11,1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23,1.24, or 1.25. In some examples, the ratio of the goss component to thebrass component to the copper component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe brass component to the S component to the copper component (or anysuitable ratio including the brass component, the S component, and thecopper component) of from 0.80 to 1.25. For example, the surface portioncan have a ratio of the brass component to the S component to the coppercomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the brass component to the Scomponent to the copper component can be less than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the goss component to the brass component to the Scomponent (or any suitable ratio including the cube component, the gosscomponent, the brass component, and the S component) of from 0.80 to1.25. For example, the surface portion can have a ratio of the cubecomponent to the goss component to the brass component to the Scomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the cube component to the gosscomponent to the brass component to the S component can be less than1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the goss component to the brass component to thecopper component (or any suitable ratio including the cube component,the goss component, the brass component, and the copper component) offrom 0.80 to 1.25. For example, the surface portion can have a ratio ofthe cube component to the goss component to the brass component to thecopper component of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87,0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99,1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11,1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23,1.24, or 1.25. In some examples, the ratio of the cube component to thegoss component to the brass component to the copper component can beless than 1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe goss component to the brass component to the S component to thecopper component (or any suitable ratio including the goss component,the brass component, the S component, and the copper component) of from0.80 to 1.25. For example, the surface portion can have a ratio of thegoss component to the brass component to the S component to the coppercomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the goss component to the brasscomponent to the S component to the copper component can be less than1.00.

In some non-limiting examples, the surface portion can have a ratio ofthe cube component to the goss component to the brass component to the Scomponent to the copper component (or any suitable ratio including thecube component, the goss component, the brass component, the Scomponent, and the copper component) of from 0.80 to 1.25. For example,the surface portion can have a ratio of the cube component to the gosscomponent to the brass component to the S component to the coppercomponent of 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89,0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01,1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13,1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, or1.25. In some examples, the ratio of the cube component to the gosscomponent to the brass component to the S component to the coppercomponent can be less than 1.00.

In some aspects, an aluminum alloy article having a portion that has lowvolume fractions of a cube texture component, a goss texture component,a brass texture component, an S texture component, and a copper texturecomponent, such as volume fractions that are between 0% and 1%, or thatis substantially free of recrystallization texture (e.g., an isotropictexture, or a texture-less surface) in any direction relative to arolling direction of the aluminum alloy article (e.g., longitudinal,transverse or diagonal) can provide an aluminum alloy having isotropicmechanical properties in any direction relative to the rolling directionof the aluminum alloy article. For example, an aluminum alloy articlehaving isotropic mechanical properties can provide an aluminum alloyarticle that does not exhibit anisotropic forming in, for example, thediagonal direction while exhibiting isotropic forming in thelongitudinal and/or transverse direction.

In some examples, comparative aluminum alloy articles may correspond toan aluminum alloy article that can be direct chill cast from a moltenaluminum alloy to form an aluminum alloy ingot. The aluminum alloy ingotcan then be homogenized and hot rolled to an intermediate gauge aluminumalloy plate. The intermediate gauge aluminum alloy plate can optionallyfurther be cold rolled to a final gauge aluminum alloy article.Comparative aluminum alloy articles can have a plurality of surfaceportions having a dominant texture component. For example, a firstsurface portion can be dominated by a cube texture and at least a secondsurface portion can be dominated by a goss texture component. Thus, thediagonal direction relative to the rolling direction of the comparativealuminum alloy article can have an anisotropic recrystallizationtexture, wherein a first surface portion can be dominated by cubetexture and at least a second surface portion can be dominated by a gosstexture component. A lower amount of thinning during rolling in thediagonal direction can be caused by splitting surface portions (e.g.,pulling the first surface portion away from the at least second surfaceportion) in the diagonal direction relative to the rolling directionduring forming. An exemplary aluminum alloy article, produced accordingto methods described below, can have an isotropic surface texture in anydirection relative to the rolling direction and provide uniform thinningin any direction relative to the rolling direction.

Aluminum Alloy Rolled Article Gauges and Compositions

In some non-limiting examples, aluminum alloy rolled articles can beproduced in a plate gauge, a shate gauge, or a sheet gauge, as describedabove. In some aspects, the aluminum alloy rolled article can beproduced from a molten aluminum alloy. The molten aluminum alloy can bea 5xxx series aluminum alloy or a 6xxx series aluminum alloy.

Non-limiting exemplary AA5xxx series aluminum alloys include AA5005,AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110,AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019,AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026,AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149,AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150,AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052,AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354,AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356,AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C,AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A,AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B,AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, and AA5088.

Non-limiting exemplary AA6xxx series aluminum alloys include AA6101,AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003,AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305,AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A,AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016,AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024,AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041,AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055,AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560,AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A,AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A,AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082,AA6082A, AA6182, AA6091, and AA6092.

Methods of Making

An exemplary aluminum alloy rolled article can be formed by a processthat includes providing a molten aluminum alloy composition,continuously casting the molten aluminum alloy composition to form analuminum alloy cast product, homogenizing the aluminum alloy castproduct to form a homogenized aluminum alloy cast product, and hotrolling the homogenized aluminum alloy cast product to form the aluminumalloy rolled article having a thickness of no more than 7 mm, such asbetween 0.01 mm and 7 mm, between 0.01 mm and 6 mm, between 0.01 mm and5 mm, between 0.01 mm and 4 mm, between 0.01 mm and 3 mm, or between0.01 mm and 2 mm. The rolling can be carried out at a temperature of noless than 300° C. The exemplary aluminum alloy rolled article can beformed by a process that does not include cold rolling. Optionally, theexemplary aluminum alloy rolled article can be subjected to quenchingafter the rolling. FIG. 1 provides a schematic example of a method andsystem of making an aluminum alloy rolled article. In embodiments, FIG.1 provides an overview of a process referred to as a hot roll to finalgauge and temper.

Continuous Casting

The aluminum alloy products described herein can be cast using acontinuous casting (CC) process. The continuous casting process can beperformed, for example, by way of the use of twin belt casters, twinroll casters, or block casters.

As illustrated in FIG. 1, in some examples, a method of making analuminum alloy rolled article includes providing a molten aluminum alloy105 and continuously injecting the molten metal from a molten metalinjector into a continuous caster 110 to form an aluminum alloy castproduct 115. The method also can include withdrawing the aluminum alloycast product, such as a cast aluminum alloy sheet, plate, or shate, froman exit of the continuous caster.

Rolling

The aluminum alloy cast product 115 can then be processed by anysuitable means. Optionally, the processing steps can be used to preparealuminum alloy rolled articles. Such processing steps include, but arenot limited to, homogenization, which may occur as illustrated in FIG. 1at block 120, and hot rolling, which may occur as illustrated in FIG. 1at section 125. In some non-limiting examples, as explained in moredetail below, a continuously cast aluminum alloy product, such as a 6xxxseries aluminum alloy or a 5xxx series aluminum alloy, can be hot rolledto a final gauge. The processing can be performed without a cold rollingstep (i.e., the cast product can be rolled to a final gauge without coldrolling). In some cases, hot rolling a continuously cast aluminum alloyproduct to a final gauge can provide an isotropic recrystallizationtexture within a surface of the aluminum alloy rolled article therebyformed. In some further cases, hot rolling a continuously cast aluminumalloy product to a final gauge can improve formability by providing analuminum alloy rolled article having isotropic mechanical properties.

Optionally, homogenization can be performed immediately after casting.Optionally, the temperature of the aluminum alloy cast product 115 isnot permitted to fall below 400° C. between casting and homogenizing.The homogenization temperature can be between 400° C. and 600° C., forexample. In some examples, homogenization may be useful for maintaininga temperature of the cast alloy at a particular value or between a rangeof values for a duration of time, such as up to 1, 2, 3, 4, 5, 6, 7, 8,9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26,27, 28, 29, or 30 hours in some examples. In some examples,homogenization may be useful for providing the cast alloy to a hotrolling stage at a particular starting temperature. After homogenizationis performed at block 120, the aluminum alloy cast product 115 may bereferred to as a homogenized aluminum alloy cast product.

Optionally, the hot rolling step can be performed immediately aftercasting or following homogenization. The hot rolling temperature can beat least 300° C., such as between 300° C. and 550° C. For example, thehot rolling temperature can be at least 300° C., at least 310° C., atleast 320° C., at least 330° C., at least 340° C., at least 350° C., atleast 360° C., at least 370° C., at least 380° C., at least 390° C., atleast 400° C., at least 410° C., at least 420° C., at least 430° C., atleast 440° C., at least 450° C., at least 460° C., at least 470° C., atleast 480° C., at least 490° C., at least 500° C., at least 510° C., atleast 520° C., at least 530° C., at least 540° C., or up to 550° C.Optionally, the hot rolling temperature can be or include therecrystallization temperature of the aluminum alloy. The homogenizedaluminum alloy cast product or aluminum alloy cast product entering intothe hot rolling stage can have a temperature of between 400° C. and 550°C., for example.

During the hot rolling step, the gauge of the aluminum alloy castproduct is reduced in thickness. In some cases, the total amount ofreduction of thickness during hot rolling can be at or less than 85%,80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, or 15%.In some cases, the cast product can be a metal sheet wherein the finalgauge of the rolled article is 7 mm or less, 6 mm or less, 5 mm or less,4 mm or less, 3 mm or less, 2 mm or less, 1.9 mm or less, 1.8 mm orless, 1.7 mm or less, 1.6 mm or less, 1.5 mm or less, 1.4 mm or less,1.3 mm or less, 1.2 mm or less, 1.1 mm, 1.0 mm or less, 0.9 mm or less,0.8 mm or less, 0.7 mm or less, 0.6 mm or less, 0.5 mm or less, 0.4 mmor less, 0.3 mm or less, 0.2 mm or less, or as small as 0.1 mm. Uponexiting the hot rolling stage, the aluminum alloy rolled article canhave a temperature of between 300° C. and 500° C., for example.

Optional Processing Steps

The method can optionally include a step of quenching the aluminum alloyrolled article after hot rolling, as illustrated at element 130 ofFIG. 1. The aluminum alloy rolled article can be cooled to a temperatureat or below about 300° C. in the quenching step, such as to atemperature between 50° C. and 300° C. For example, the aluminum alloyrolled article can be cooled to a temperature at or below 290° C., at orbelow 280° C., at or below 270° C., at or below 260° C., at or below250° C., at or below 240° C., at or below 230° C., at or below 220° C.,at or below 210° C., at or below 200° C., at or below 190° C., at orbelow 180° C., at or below 170° C., at or below 160° C., at or below150° C., at or below 140° C., at or below 130° C., at or about 120° C.,at or below 110° C., or at or below 100° C. The aluminum alloy rolledarticle can be quenched immediately after hot rolling or within a shortperiod of time thereafter (e.g., within 10 hours or less, 9 hours orless, 8 hours or less, 7 hours or less, 6 hours or less, 5 hours orless, 4 hours or less, 3 hours or less, 2 hours or less, 1 hour or less,or 30 minutes or less). The aluminum alloy rolled article can optionallybe coiled and stored after hot rolling and/or quenching, as illustratedat element 135 of FIG. 1.

Methods of Use Automotive and Transportation

Aluminum alloy articles of manufacture produced from aluminum alloyrolled articles, such as sheets and shates, described herein can be usedin automotive applications and other transportation applications,including aircraft and railway applications. For example, the aluminumalloy rolled articles can be used to prepare automotive structuralparts, such as outer panels, inner panels, side panels, bumpers, sidebeams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars,B-pillars, and C-pillars), inner hoods, outer hoods, or trunk lidpanels. The aluminum alloy rolled articles and methods described hereincan also be used in aircraft or railway vehicle applications, toprepare, for example, external and internal panels.

Electronics

The aluminum alloy rolled articles described herein can also be used inelectronics applications. For example, the aluminum alloy rolledarticles and methods described herein can be used to prepare housingsfor electronic devices, including mobile phones and tablet computers. Insome examples, the aluminum alloy rolled articles can be used to prepareanodized quality sheets and materials.

Containment

The aluminum alloy rolled articles described herein can be used incontainer applications, including aluminum can body stock and aluminumcan end stock.

Mechanical Properties

The aluminum alloy rolled articles described herein can have a surfacethat has low volume fractions of a cube texture component, a gosstexture component, a brass texture component, an S texture component,and a copper texture component, such as volume fractions that arebetween 0% and 1%, or that is substantially free of recrystallizationtexture. An aluminum alloy article having a surface of this nature(e.g., an isotropic surface) can provide an aluminum alloy articlehaving isotropic mechanical properties (e.g., mechanical properties thatcan be uniform in any direction across the surface relative to a rollingdirection of the aluminum alloy cast product). An aluminum alloy rolledarticle having isotropic mechanical properties can be subjected toforming processes that demand a high formability. In some non-limitingexamples, the aluminum alloy rolled articles described herein can besubjected to complex forming processes. In some further examples, thealuminum alloy rolled articles described herein can be subjected tomulti-step forming processes.

Various advantages may be achieved using the aluminum alloy castproducts and aluminum alloy rolled articles and methods of makingaluminum alloy cast products and aluminum alloy rolled articlesdescribed herein. For example, as noted above, the aluminum alloy rolledarticles may exhibit advantageous mechanical properties, such as anisotropic surface. Additionally, the aluminum alloy rolled articles mayexhibit isotropic thinning properties when subjected to strain, meaningthat the aluminum alloy rolled articles may have a tendency to thinduring straining by an approximately equal amount in all directions.This property may provide a benefit in forming articles of manufactureusing the aluminum alloy rolled articles described herein.

For example, conventionally cold-rolled aluminum may exhibit mechanicalanisotropy, meaning the mechanical properties of the cold-rolledaluminum are not uniform along different directions (e.g., rollingdirection, transverse direction, diagonal direction, etc.). Whencold-rolled aluminum is subjected to forming or drawing to generate anarticle of manufacture, the material may have a tendency to thindifferent amounts upon being subjected to strain along differentdirections. Depending on the shape and specific form of the article ofmanufacture, the article may thin significantly more in some locationsthan in others. When subjected to sufficient strain and thinning alongdirections that have a tendency to thin much more than others (e.g.,along a diagonal direction), the article of manufacture may break,fracture, or otherwise fail at these critical points or along thesecritical directions.

Due to the isotropic mechanical properties, the presently describedaluminum alloy cast products and aluminum alloy rolled articles overcomethese and other processing difficulties. By having a surface that haslow volume fractions of a cube texture component, a goss texturecomponent, a brass texture component, an S texture component, and acopper texture component, such as volume fractions that are between 0%and 1%, or that is substantially free of recrystallization texture, thesurface can exhibit isotropic mechanical properties, such as theLangford coefficient (R-value), such that forming an article ofmanufacture using the presently described aluminum alloy rolled articlesdoes not result in the same failure along the above-described criticaldirections or at the above-described critical points.

The following examples will serve to further illustrate the presentinvention without, at the same time, however, constituting anylimitation thereof. On the contrary, it is to be clearly understood thatresort can be had to various embodiments, modifications and equivalentsthereof which, after reading the description herein, can suggestthemselves to those skilled in the art without departing from the spiritof the invention.

Example A

Aluminum alloy samples were provided according to methods describedherein. Alloys 6111, 6451, and 5754 were produced by exemplary methods,including continuous casting, homogenization and hot rolling to a finalgauge. Alloys 6451 and 5754 were further produced by an optional methodfor comparison, including continuous casting, homogenization and coldrolling to a final gauge. Alloys 6111, 6451, and 5754 were producedaccording to comparative methods, including direct chill casting,homogenization, hot rolling, and cold rolling. The aluminum alloysamples were analyzed for recrystallization texture. FIG. 1 is a barchart showing results of recrystallization texture analysis. A cubetexture component (left histogram in each pair) and a brass texturecomponent (right histogram in each pair) are shown form comparison.Texture component volume fraction (%) is shown for cube and brasstexture components. Continuously cast alloys are referred to herein as“CC” and direct chill cast alloys are referred to herein as “DC.”Processing methods are described in Table 1 below:

TABLE 1 Processing Methods HRTGT Hot roll to final gauge and temper HR +CR Hot roll and cold roll CR Cold roll HR Hot roll

Hot roll to final gauge and temper indicates the exemplary methoddescribed herein, including continuous casting, homogenization, and hotrolling to a final gauge, as shown in FIG. 1. The exemplary methodprovided aluminum alloy rolled articles having a uniform distribution oftexture components, as shown in FIGS. 2, 3, and 4 and described below.The comparative methods provided an aluminum alloy rolled article havingan anisotropic recrystallization texture, wherein the surface wasdominated by cube texture. Isotropic surface recrystallization texturewas provided by the exemplary method described herein.

FIGS. 2, 3, and 4 are bar charts showing results of recrystallizationtexture analysis. A cube texture component (left histogram in each set),a goss texture component (second from the left histogram in each set), abrass texture component (center histogram in each set), an S texturecomponent (fourth from the left histogram in each set) and a coppertexture component (right histogram in each set) are shown forcomparison. As evident in FIGS. 2, 3, and 4, the exemplary methodprovided aluminum alloy rolled articles having a uniform distribution oftexture components, wherein no texture component was observed having avolume fraction greater than 1% within the surface of the aluminumalloy. The comparative methods provided an aluminum alloy rolledarticles having an anisotropic recrystallization texture, wherein thesurface was dominated by cube texture. Isotropic surfacerecrystallization texture was provided by the exemplary method describedherein.

Examples 1-61

As used below, any reference to a series of examples is to be understoodas a reference to each of those examples disjunctively (e.g., “examples1-4” is to be understood as “examples 1, 2, 3, or 4”).

Example 1 is an aluminum alloy rolled article comprising a rolledsurface, wherein the rolled surface comprises a first surface portion,comprising at least a first surface portion, and wherein the firstsurface portion is substantially free of recrystallization texture orwherein the first surface portion has volume fractions of a cube texturecomponent, a goss texture component, a brass texture component, an Stexture component, and a copper texture component that are between 0%and 1%.

Example 2 is the aluminum alloy rolled article of example 1, wherein thefirst surface portion has an isotropic texture, wherein the isotropictexture comprises a plurality of texture components, wherein eachtexture component comprises less than 1 volume percent of the firstsurface portion.

Example 3 is the aluminum alloy rolled article of example 2, wherein theplurality of texture components comprise surface texture componentsselected from the group consisting of a cube component, a gosscomponent, a brass component, an S component, and a copper component.

Example 4 is the aluminum alloy rolled article of examples 1-3, whereinthe first surface portion exhibits substantially uniform thinning duringforming across the first surface portion in any direction relative to arolling direction.

Example 5 is the aluminum alloy rolled article of examples 1-4, whereinthe first surface portion has a cube component to brass component ratioof from 0.80 to 1.25.

Example 6 is the aluminum alloy rolled article of examples 1-5, whereinthe first surface portion has a cube component to goss component ratioof from 0.80 to 1.25.

Example 7 is the aluminum alloy rolled article of examples 1-6, whereinthe first surface portion has a cube component to S component ratio offrom 0.80 to 1.25.

Example 8 is the aluminum alloy rolled article of examples 1-7, whereinthe first surface portion has a cube component to copper component ratioof from 0.80 to 1.25.

Example 9 is the aluminum alloy rolled article of examples 1-8, whereinthe first surface portion has a goss component to brass component ratioof from 0.80 to 1.25.

Example 10 is the aluminum alloy rolled article of examples 1-9, whereinthe first surface portion has a goss component to S component ratio offrom 0.80 to 1.25.

Example 11 is the aluminum alloy rolled article of examples 1-10,wherein the first surface portion has a goss component to coppercomponent ratio of from 0.80 to 1.25.

Example 12 is the aluminum alloy rolled article of examples 1-11,wherein the first surface portion has a brass component to S componentratio of from 0.80 to 1.25.

Example 13 is the aluminum alloy rolled article of examples 1-12,wherein the first surface portion has a brass component to coppercomponent ratio of from 0.80 to 1.25.

Example 14 is the aluminum alloy rolled article of examples 1-13,wherein the first surface portion has an S component to copper componentratio of from 0.80 to 1.25.

Example 15 is the aluminum alloy rolled article of examples 1-14,wherein the first surface portion has a cube component to goss componentto brass component ratio of from 0.80 to 1.25.

Example 16 is the aluminum alloy rolled article of examples 1-15,wherein the first surface portion has a cube component to goss componentto S component ratio of from 0.80 to 1.25.

Example 17 is the aluminum alloy rolled article of examples 1-16,wherein the first surface portion has a cube component to goss componentto copper component ratio of from 0.80 to 1.25.

Example 18 is the aluminum alloy rolled article of examples 1-17,wherein the first surface portion has a goss component to brasscomponent to S component ratio of from 0.80 to 1.25.

Example 19 is the aluminum alloy rolled article of examples 1-18,wherein the first surface portion has a goss component to brasscomponent to copper component ratio of from 0.80 to 1.25.

Example 20 is the aluminum alloy rolled article of examples 1-19,wherein the first surface portion has a brass component to S componentto copper component ratio of from 0.80 to 1.25.

Example 21 is the aluminum alloy rolled article of examples 1-20,wherein the first surface portion has a cube component to goss componentto brass component to S component ratio of from 0.80 to 1.25.

Example 22 is the aluminum alloy rolled article of examples 1-21,wherein the first surface portion has a cube component to goss componentto brass component to copper component ratio of from 0.80 to 1.25.

Example 23 is the aluminum alloy rolled article of examples 1-22,wherein the first surface portion has a goss component to brasscomponent to S component to copper component ratio of from 0.80 to 1.25.

Example 24 is the aluminum alloy rolled article of examples 1-23,wherein the first surface portion has a cube component to goss componentto brass component to S component to copper component ratio of from 0.80to 1.25.

Example 25 is the aluminum alloy rolled article of examples 1-24,wherein the aluminum alloy rolled article has a width or length of from6.5 mm to 40 m.

Example 26 is the aluminum alloy rolled article of examples 1-25,wherein the aluminum alloy rolled article comprises or is composed of a5xxx aluminum alloy.

Example 27 is the aluminum alloy rolled article of examples 1-26,wherein the aluminum alloy rolled article comprises or is composed of a6xxx aluminum alloy.

Example 28 is the aluminum alloy rolled article of examples 1-27,wherein the aluminum alloy rolled article is formed by a process thatdoes not comprise cold rolling.

Example 29 is the aluminum alloy rolled article of examples 1-28,wherein the aluminum alloy rolled article is formed by a process thatcomprises: providing a molten aluminum alloy composition; continuouslycasting the molten aluminum alloy composition to form an aluminum alloycast product; homogenizing the aluminum alloy cast product to form ahomogenized aluminum alloy cast product; and rolling the homogenizedaluminum alloy cast product to form the aluminum alloy rolled articlehaving a thickness of between 0.01 mm and 7 mm, wherein the rolling iscarried out at a temperature of between 300° C. and 550° C.

Example 30 is a method for making an aluminum alloy rolled article,comprising: providing a molten aluminum alloy composition; continuouslycasting the molten aluminum alloy composition to form an aluminum alloycast product; homogenizing the aluminum alloy cast product to form ahomogenized aluminum alloy cast product; and rolling the homogenizedaluminum alloy cast product to form an aluminum alloy rolled articlehaving a thickness of between 0.01 mm and 7 mm, wherein the rolling iscarried out at a temperature of between 300° C. and 550° C.

Example 31 is the method of example 30, wherein homogenizing thealuminum alloy cast product includes controlling a homogenizationtemperature of the aluminum alloy cast product after exiting from acontinuous caster, wherein the homogenization temperature is between400° C. and 600° C.

Example 32 is the method of examples 30-31, wherein the aluminum alloycast product is not cooled to below 400° C. before the homogenizing.

Example 33 is the method of example 30-32, wherein rolling thehomogenized aluminum alloy cast product includes controlling a rollingtemperature during rolling, wherein a starting temperature of therolling is between 400° C. and 550° C., and wherein an exit temperatureof the rolling is between 300° C. and 500° C.

Example 34 is the method of examples 30-33, wherein rolling thehomogenized aluminum alloy cast product includes maintaining thetemperature at or above a recrystallization temperature of thehomogenized aluminum alloy cast product.

Example 35 is the method of examples 30-34, further comprising,following the rolling, subjecting the aluminum alloy rolled article toquenching.

Example 36 is the method of examples 30-35, wherein the method does notcomprise direct chill casting.

Example 37 is the method of examples 30-36, wherein the method does notcomprise cold rolling the aluminum alloy rolled article to a finalthickness.

Example 38 is the method of examples 30-37, wherein the aluminum alloyrolled article comprises at least a first surface portion, and whereinthe first surface portion is substantially free of recrystallizationtexture or wherein the first surface portion has volume fractions of acube texture component, a goss texture component, a brass texturecomponent, an S texture component, and a copper texture component thatare between 0% and 1%.

Example 39 is an aluminum alloy rolled article, which is formed by aprocess comprising: providing a molten aluminum alloy composition;continuously casting the molten aluminum alloy composition to form analuminum alloy cast product; homogenizing the aluminum alloy castproduct to form a homogenized aluminum alloy cast product; and rollingthe homogenized aluminum alloy cast product to form the aluminum alloyrolled article having a thickness of between 0.01 mm and 7 mm, whereinthe rolling is carried out at a temperature of between 300° C. and 550°C.

Example 40 is the aluminum alloy rolled article of example 39, whereinhomogenizing the aluminum alloy cast product includes controlling ahomogenization temperature of the aluminum alloy cast product afterexiting from a continuous caster, wherein the homogenization temperatureis between 400° C. and 600° C.

Example 41 is the aluminum alloy rolled article of examples 39-40,wherein the aluminum alloy cast product is not cooled to below 400° C.before the homogenizing.

Example 42 is the aluminum alloy rolled article of examples 39-41,wherein rolling the homogenized aluminum alloy cast product includescontrolling a rolling temperature during rolling, wherein a startingtemperature of the rolling is between 400° C. and 550° C., and whereinan exit temperature of the rolling is between 300° C. and 500° C.

Example 43 is the aluminum alloy rolled article of examples 39-42,wherein rolling the homogenized aluminum alloy cast product includesmaintaining the temperature at or above a recrystallization temperatureof the homogenized aluminum alloy cast product.

Example 44 is the aluminum alloy rolled article of examples 39-43,wherein the process further comprises, following the rolling, subjectingthe aluminum alloy rolled article to quenching.

Example 45 is the aluminum alloy rolled article of examples 39-44,wherein the process does not comprise direct chill casting.

Example 46 is the aluminum alloy rolled article of examples 39-45,wherein the process does not comprise cold rolling the aluminum alloyrolled article to a final thickness.

Example 47 is the aluminum alloy rolled article of examples 39-46,comprising at least a first surface portion, and wherein the firstsurface portion is substantially free of recrystallization texture orwherein the first surface portion has volume fractions of a cube texturecomponent, a goss texture component, a brass texture component, an Stexture component, and a copper texture component that are between 0%and 1%.

Example 48 is the aluminum alloy rolled article of example 47, whereinthe first surface portion has an isotropic texture.

Example 49 is the aluminum alloy rolled article of example 48, whereinthe isotropic texture comprises a plurality of texture components, andwherein each texture component comprises less than 1 volume percent ofthe first surface portion.

Example 50 is the aluminum alloy rolled article of examples 47-49,wherein the first surface portion exhibits substantially uniformthinning during forming across the first surface portion in anydirection relative to a rolling direction.

Example 51 is an aluminum alloy article of manufacture, comprising analuminum alloy rolled article of examples 1-29, an aluminum alloy rolledarticle of any one of examples 39-50, or an aluminum alloy rolledarticle formed by the method of any one of examples 30-38.

Example 52 is the aluminum alloy article of manufacture of example 51,wherein the aluminum alloy rolled article is subjected to a stamping,forming, or drawing process.

Example 53 is the aluminum alloy article of manufacture of examples51-52, wherein the aluminum alloy article of manufacture is anautomotive body part.

Example 54 is the aluminum alloy article of manufacture of example 53,wherein the automotive body part comprises a structural part.

Example 55 is the aluminum alloy article of manufacture of example 53,wherein the automotive body part is an outer panel.

Example 56 is the aluminum alloy article of manufacture of examples51-52, wherein the aluminum alloy article of manufacture is anelectronics device housing.

Example 57 is the aluminum alloy article of manufacture of examples51-52, wherein the aluminum alloy article of manufacture is an aerospacebody part.

Example 58 is the aluminum alloy article of manufacture of examples51-52, wherein the aluminum alloy article of manufacture is atransportation body part.

Example 59 is the aluminum alloy article of manufacture of examples51-52, wherein the aluminum alloy article of manufacture is a containerpart.

Example 60 is the aluminum alloy article of manufacture of example 59,wherein the aluminum alloy article of manufacture is a storage tank.

Example 61 is the aluminum alloy article of manufacture of example 59,wherein the aluminum alloy article of manufacture is an aluminum canend.

All patents, publications and abstracts cited above are incorporatedherein by reference in their entirety. The foregoing description of theembodiments, including illustrated embodiments, has been presented onlyfor the purpose of illustration and description and is not intended tobe exhaustive or limiting to the precise forms disclosed. Numerousmodifications, adaptations, and uses thereof will be apparent to thoseskilled in the art.

What is claimed is:
 1. A method for making an aluminum alloy rolledarticle, comprising: providing a molten aluminum alloy composition;continuously casting the molten aluminum alloy composition to form analuminum alloy cast product; homogenizing the aluminum alloy castproduct to form a homogenized aluminum alloy cast product; and rollingthe homogenized aluminum alloy cast product to form an aluminum alloyrolled article having a thickness of between 0.01 mm and 7 mm, whereinthe rolling is carried out at a temperature of between 300° C. and 550°C.
 2. The method of claim 1, wherein homogenizing the aluminum alloycast product includes controlling a homogenization temperature of thealuminum alloy cast product after exiting from a continuous caster,wherein the homogenization temperature is between 400° C. and 600° C. 3.The method of claim 1, wherein the aluminum alloy cast product is notcooled to below 400° C. before the homogenizing.
 4. The method of claim1, wherein rolling the homogenized aluminum alloy cast product includescontrolling a rolling temperature during rolling, wherein a startingtemperature of the rolling is between 400° C. and 550° C., and whereinan exit temperature of the rolling is between 300° C. and 500° C.
 5. Themethod of claim 1, wherein rolling the homogenized aluminum alloy castproduct includes maintaining the temperature at or above arecrystallization temperature of the homogenized aluminum alloy castproduct.
 6. The method of claim 1, further comprising, following therolling, subjecting the aluminum alloy rolled article to quenching. 7.The method of claim 1, wherein the method does not comprise direct chillcasting.
 8. The method of claim 1, wherein the method does not comprisecold rolling the aluminum alloy rolled article to a final thickness. 9.The method of claim 1, wherein the aluminum alloy rolled articlecomprises at least a first surface portion having volume fractions of acube texture component, a goss texture component, a brass texturecomponent, an S texture component, and a copper texture component thatare between 0% and 1%.
 10. An aluminum alloy rolled article, which isformed by a process comprising: providing a molten aluminum alloycomposition; continuously casting the molten aluminum alloy compositionto form an aluminum alloy cast product; homogenizing the aluminum alloycast product to form a homogenized aluminum alloy cast product; androlling the homogenized aluminum alloy cast product to form the aluminumalloy rolled article having a thickness of between 0.01 mm and 7 mm,wherein the rolling is carried out at a temperature of between 300° C.and 550° C.
 11. The aluminum alloy rolled article of claim 10, whereinhomogenizing the aluminum alloy cast product includes controlling ahomogenization temperature of the aluminum alloy cast product afterexiting from a continuous caster, wherein the homogenization temperatureis between 400° C. and 600° C.
 12. The aluminum alloy rolled article ofclaim 10, wherein the aluminum alloy cast product is not cooled to below400° C. before the homogenizing.
 13. The aluminum alloy rolled articleof claim 10, wherein rolling the homogenized aluminum alloy cast productincludes controlling a rolling temperature during rolling, wherein astarting temperature of the rolling is between 400° C. and 550° C., andwherein an exit temperature of the rolling is between 300° C. and 500°C.
 14. The aluminum alloy rolled article of claim 10, wherein rollingthe homogenized aluminum alloy cast product includes maintaining thetemperature at or above a recrystallization temperature of thehomogenized aluminum alloy cast product.
 15. The aluminum alloy rolledarticle of claim 10, wherein the process further comprises, followingthe rolling, subjecting the aluminum alloy rolled article to quenching.16. The aluminum alloy rolled article of claim 10, wherein the processdoes not comprise direct chill casting.
 17. The aluminum alloy rolledarticle of claim 10, wherein the process does not comprise cold rollingthe aluminum alloy rolled article to a final thickness.
 18. The aluminumalloy rolled article of claim 10, comprising at least a first surfaceportion having volume fractions of a cube texture component, a gosstexture component, a brass texture component, an S texture component,and a copper texture component that are between 0% and 1%.
 19. Thealuminum alloy rolled article of claim 18, wherein the first surfaceportion has an isotropic texture.
 20. The aluminum alloy rolled articleof claim 18, wherein the first surface portion exhibits substantiallyuniform thinning during forming across the first surface portion in anydirection relative to a rolling direction.